PDF File - Planet CPR Product Safety Compliance Research Report
Contents
1. document titled Declaration of Conformity DoC The DoC lists to what EU Directives and Standards the product complies it can list required standards and or optional standards This is very important for two reasons a b c Two competing products may both have a CE mark but their CE marks could mean vastly different levels of compliance it s important that you know that the CE mark only means whatever is on the DoC You will have some choice on how much or how little you comply with for your CE mark And it can be additive including more standards over time Under this project we have focused on product safety we have identified the applicable product safety directive standard for this product below 13 CE Mark Process To sell your product in the European Union the product must bear the CE mark For your type of product the CE mark program is self certification not required to certify the product with an independent lab test report with data is sufficient without ongoing production inspections The overall CE process is a b c Determine the EU Directives applicable to your product For each EU Directive applicable to your product determine the standard s under the directive that best fits your type of product based on the scope of each standard Verify that your product meets the standard s identified in step b this includes construction labeling and instruction manual evalu2. product specifications as well as the name and address of the supplier It is also advisable to reproduce all product markings in the manual adding related details as appropriate a Each turbine should be provided with installation instructions Details on fixing the turbine in place inlet and outlet connections and any details on specific hardware and plumbing to use Adequate warnings should be included to protect the user from high pressure and the rotating shaft s Considering your intended international customers pictures with attention getting arrows highlighting are advisable to help minimize wording that could need translation 2 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Priei Ge o Compliance amp Certification Compliance refers to verifying that your product complies with the standards Certification refers to having a 3 party certify that your product complies with the standards 7 General Certification Comments a As your product is mechanical only no electrical parts it is quite possible that you will find that no official certification requirements apply to the turbine In fact you may wish to pursue sales of your product while listening to feedback from the customer as to local regulatory requirements Many countries which are not highly developed may have no regulatory requirements e As we discussed sometimes the prospect for jobs and or the gener
3. G Pr iri GeR o November 1 2011 Planet CPR Product Safety Compliance Research Report Please note that this research project was limited to an overall review of the available product information and prototype external review only This project and report is excellent preparation for a full UL CSA CE IEC evaluation However it is not a substitute for the detailed clause by clause review that occurs during the actual certification evaluation which also includes compliance and validation testing The goal of this project was to identify the path to compliance and provide guidance towards compliance While every effort was made to be as complete and thorough as possible additional issues could be identified during the actual certification evaluation General 1 Turbine Classification During our discussions you mentioned model variations that cover a considerable span in output power as recall ratings as high as 30 MW were mentioned as a possibility Please note that the Hydro turbine industry has created the following turbine classifications based on output rating these are relevant as different standards apply to different turbine classifications a Micro Hydro up to 50 KW or up to 100 KW depending on the source standard b Mini Hydro up to 1 MW c Small Scale Hydro up to 30 MW 2 Turbine vs Turbine Generating System a The turbine itself being a fully mechanical device with no electrical parts is unlik
4. andard has been identified as EN61116 as noted above b Turbine System with Generator comply with the Machinery Directive amp the Low Voltage Directive electrical safety and possibly the EMC directive depends on design of generator For the Low Voltage Directive the generator standard would apply therefore if you do decide to develop a system be sure to select a generator that can provide a Declaration of Conformity and Certification reports that show the generator meets the Low Voltage Directive and the EMC Directive if applicable if high frequency electrical circuits are incorporated in the generator design Priei Ge o 15 International Compliance This applies to all countries beyond the US Canada amp the European Union The first step is to identify whether the country is a member of the IEC Countries who are members of the IEC agree to use the IEC standard as their country s national standard We have verified that India and South Africa are IEC members Therefore compliance with IEC61116 is applicable for these countries Since IEC61116 is the same as EN61116 if you prepare a CE report to the EN standard it will also satisfy most other countries outside the EU e Also see Attachment C regarding international standards for tendering documents 16 Compliance Issues In a brief review of the turbine requirements per the standard IEC EN61116 we identified these items to consider We recommend th
5. at you obtain a copy of this standard and familiarize yourself with the small scale turbine and turbine generator system requirements a Maintenance The standard specifies that the material of the unit especially the runner and other parts subject to wear should be easily repairable There doesn t appear to be any way to easily access the inside of your turbine b Corrosion amp Wear Protection The standard places a lot of emphasis on this topic c Flexible Couplings A coupling is recommended in the standard to avoid alignment issues We also discussed during my visit if this could help with a hard start of the turbine slam start to the generator Compliance amp Validation Testing See Attachment B for proposed test plan 17 Your Testing Comments Most of the parameters you discussed with Clark Testing are included in the test plan per attachment B You mention 10 data points which is a good number considering your objectives for the test data compliance validation and marketing purposes 5 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Next Step a Let s schedule a phone conversation to review the report together b Once we are clear on what testing validation reports you would like performed and how long we think that will take will provide these details to our Sales Team so that they may provide you with a quote for the test phase of the project c If you would like any assis
6. ation of electricity may outweigh any local inspector regulatory concerns in lesser developed countries However since your product is attached to an electrical generator it is likely that some government inspectors will require that the hydraulic generator system turbine plus generator be certified If you find this to be a problem you may wish to identify and or provide suitably certified generators See comments in item 2 above 8 Product Safety Standard Overview a US product safety standards are typically written and titled UL Underwriters Laboratories Canadian CAN product safety standards are typically written and titled CSA Canadian Standards Associations European Union safety standards CE mark program are prepared by CENELEC and are titled EN European Normalized International safety standards beyond North America amp the EU are written and titled IEC International Electro technical Committee 9 General Product Safety Hazard Review In general there are 6 hazards the UL and CSA standards focus on protecting the user See Attachment A for a review of the 6 hazards for your product 10 Safety Standards a b US UL There are no established US UL standards for water turbines A generator turbine system is to comply with UL508 the Standard for Industrial Control Equipment CAN CSA There are no established CAN CSA standards for water turbines A generat
7. ation to the standards plus testing and a compliance report e The manufacturer is to maintain a Technical Construction File TCF for each product which includes a report showing clause by clause compliance with the standard the test data copies of the manuals labels schematics diagrams etc If European authorities ever question your DoC they have the right to request your TCF to verify compliance of products bearing the CE mark Prepare a Declaration of Conformity DoC listing the Directive s and Standard s with which your product complies The DoC must be signed by an officer of your company Affix the CE mark to your product buy labels www productsafeT com or print yourself Include at least 3 copies of your signed DoC with each shipment i e 3 copies of the DoC with the Packing List allowing each inspector to take a copy Consider including a copy of your DoC with each unit i e print in the back of your manual 4 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 K G 14 CE Mark Hydro Turbine a Turbine Only comply with the Machinery Directive mechanical safety The Machinery Directive includes a list of over 800 standards to be considered most of the standards are product specific so many will not be applicable to the turbine The exact standards that apply are determined during an initial Risk Assessment which is part of the CE certification process The primary st
8. ed by a National Recognized Accrediting Body in accordance with IS01725 Original calibration documentation must be available for inspection at the time of testing A copy of all calibration documentation must also be provided at the time of testing 11 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Pr iri GeR o Attachment C IEC Standards on Tendering Hydro Turbines During our meeting we discussed the possibility that foreign buyers would require you to quote sales through a tendering system Coincidentally during our research we found that the IEC has a series of standards on the tendering documents for Hydro Turbines We are not familiar with these standards and their contents However we wanted to bring these to your attention in case they may be beneficial for your sales process Refer to www iec ch and search under IEC61336 to access the following list of standards From there you can see a preview of each standard to determine their benefit to you you can also purchase any IEC standard directly from this site IEC TR 61366 1 ed1 0 1998 03 Hydraulic turbines storage pumps and pump turbines Tendering Documents Part 1 General and annexes IEC TR 61366 2 ed1 0 1998 03 Hydraulic turbines storage pumps and pump iurbines Tendering Documents Part 2 Guidelines for technical specifications for Francis turbines IEC TR 61366 3 ed1 0 1998 03 Hydraulic turbines storage pum
9. ely to be required by an inspection authority to have product certification b However the turbine is not a standalone device In many cases it is likely to be connected to an electrical generator as well as other possible electrical devices The overall system is likely to be inspected by the local authorities Any compliance problems with the generator will prevent the system from being operated Consequently you may wish to consider recommending or providing a generator which you know is certified for the installation country location c Werecommend that you consider providing as much detail on the recommended system system parts system preparation and system installation as possible in an effort to help limit installation problems Providing a raw turbine to the wrong group could lead to haphazard installation and poor results results that may bear negatively on your product company even though you are not responsible for or in control of the installation j 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Priei Ge o 3 Country of Destination The first step towards compliance is to identify the countries in which you plan to market For compliance purposes countries are grouped as follows a US Canada b c European Union d International all countries other than the US CAN amp the EU countries 4 Product Specifications Typical required specifications for wate
10. ion of efficiency ratings for any couplings drive systems between the turbine and the generator We discussed the possibility of you providing these couplings in which case their efficiency of should be calculated and verified e Calculate the overall turbine system efficiency with without couplings 7 Calculate the actual turbine efficiency e Actual turbine efficiency actual turbine power output theoretical gross turbine power output m x g x Hnet o m mass flow rate in kg s the flow rate in liters second measured per step 1 o g gravitational constant 9 81 m s o Hnet the net head calculated in step 4 8 Compare the measured turbine efficiency step 7 to the claimed efficiency step 3 e Tolerance of 10 9 Multiple Flow Rate Test Points e At least one point on the efficiency curve between 50 100 efficiency should be validated You should consider if there are marketing benefits to validate multiple points on the curve NOTE testing is typically conducted in the field using the actual flow rate of the day Since you are generating your flow rate it is recommended that you consider multiple flow rate validation to avoid suspicions that you are gaming the test by picking your ideal flow rate for validation Priei Ge o Test Equipment Calibration Test equipment must be calibrated at least within the past 12 months at the time of use Calibration must have been performed by a Cal Lab that is accredit
11. ompliance D Debris in the Water This is related to your instruction manual and specifications for filtering incoming water What would occur if the wrong filter was used if the filter failed or if the filter fell off How large of debris could enter the turbine and what would be the worst case situation could debris suddenly jam the turbine while at high speed creating an explosion within the turbine E Loss of Turbine Fin If applicable what would happen if a fin became loose Is there any other internal part that could come loose or break off i e a part that could become a projectile F Other It is in your best interest to identify all possible fault failure conditions and insure that your turbine does not present a hazardous condition to persons should additional fault tests be conducted As discussed and outlined in Attachment A the primary concerns are any condition that would cause the turbine to explode or otherwise emit shrapnel and preventing water from reaching the electrical generator circuits as a result of damage to the turbine 9 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Validation Testing of the Turbine Efficiency Curve Confirmation Power performance validation is based on your rated efficiency curve for the turbine design You need to prepare an efficiency curve similar to the example shown below for each turbine model At least one point on the efficiency curve bet
12. or turbine system is to comply with CSA22 2No 14 10 the Standard for Industrial Control Equipment EU Small scale turbines are subject to EN61116 the Electromechanical Equipment Guide for Small Hydroelectric Installations http shop bsigroup com to purchase EN standards This is the primary CE mark standard for the EU Additional standards may be applicable under the Machinery Directive risk analysis the rotating machines standard may be applicable depending on your instructions e We noticed some foreign tax credit programs specify hydro turbine installations must comply with this standard to qualify d International Small scale turbines are subject to IEC61116 the Electromechanical Equipment Guide for Small Hydroelectric Installations This standard is identical to EN61116 3 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Pr iei GR o 11 US CAN Certification Initial response from US UL certification labs is that they do not want to certify the mechanical turbine only They would consider certifying the combination of the turbine and a generator For the turbine only it was recommended that a letter report with the compliance and validation test data may suffice 12 N The EU CE Program Overall Comment The first thing to know about CE is that a CE mark can mean many things in order to know what a specific CE mark means you must see the manufacturer s supporting
13. ps and pump turbines Tendering documents Part 3 Guidelines for technical specifications for Pelton turbines IEC TR 61366 4 ed1 0 1998 03 Hydraulic turbines storage pumps and pump turbines Tendering Documents Part 4 Guidelines for technical specifications for Kaplan and propeller turbines IEC TR 61366 5 ed1 0 1998 03 Hydraulic turbines storage pumps and pump turbines Tendering Documents Part 5 Guidelines for technical specifications for tubular turbines IEC TR 61366 6 ed1 0 1998 03 Hydraulic turbines storage pumps and pump iurbines Tendering Documents Part 6 Guidelines for technical specifications for pbump turbines IEC TR 61366 7 ed1 0 1998 03 Hydraulic turbines storage pumps and pump turbines Tendering Documents Part 7 Guidelines for technical specifications for storage pumps 12 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065
14. r turbines include a b c d JASS IQ O Nr N N Generic Type or description of the turbine including its layout shaft details vertical horizontal or angled Company name and contact information Product name and or model number Outline drawing giving main dimensions and locations of the output shaft s and turbine fixing points Intended method of control of water flow through the turbine Rated head and flow in the units typical for the country of destination i e head in meters and flow in liters per second Head and flow operational range Efficiency over the specified flow range Output at the rated head and flow kW at the shaft Shaft rotation speed and direction Runaway speed at maximum rated head Environmental ratings ambient temperature humidity altitude etc 5 Product Markings Typical markings required on the turbine include the following Markings and labels should be permanent a b c d e Company name or trademark Country of manufacture Model number Serial number or other specific product code e We have also seen information that suggests that it is industry practice to mark a serial number on major internal parts such as a runner or drum for maintenance purposes Product ratings 6 Instruction Installation Manual a Each turbine should be provided with a user s manual with operating instructions The users manual should also include the
15. rdless of voltage e The turbine is mechanical only it does not incorporate any electrical circuitry Therefore it does not have parts that are considered a risk of energy e However the turbine is intended to be connected and adjacent to an electrical generator As such the primary consideration for Risk of Shock is to protect the generator from damage caused by the turbine that could result in a shock hazard to the operator For example could the turbine leak and spray water onto electrical circuits of the generator or a battery storage system 3 Risk of Fire limit fuel to a fire by using certified flame rated combustible materials plastics circuit boards wiring etc and by designing the outer enclosure to contain fire if a fire should occur inside the product as a result of a fault condition e We did not identify any combustible materials used in the construction of the turbine e The primary consideration for Risk of Fire is to protect the generator from damage caused by the turbine For example could the turbine leak and spray water onto an adjacent generator electronic causing a fire 4 Risk of Injury prevent access to moving parts sharp edges etc This is the primary hazard concern for compliance of the turbine construction e The turbine should have rounded edges in all operator accessible areas e The primary concern is whether any failure mode could result in the turbine exploding or otherwise sending shrapnel flying
16. shown to be the worst case for all models in the family then it can be the only model tested In some cases testing the largest and smallest units is appropriate In other cases a greater sampling is needed Many times a single model is subjected to full testing and other sizes are subjected to one or a few tests on the variations It all depends on the design and rating differences between models Compliance Testing of the Turbine As discussed in the main body of the report certification of the turbine may not prove to be necessary Regardless you should consider the following compliance tests and the resulting effect on the turbine In general what single fault conditions could occur in use and how would the turbine respond A Maximum Bearing Temperature Are the bearings stay within their ratings this is a worst case normal operation consideration B Exceeding Runaway Speed What would occur if the input pressure exceeded the maximum rating Could a hazard occur Your installation instructions may need to mandate pressure monitoring devices with an alarm system depending on the results of this condition C Hydrostatic Pressure Test Block the output of the turbine and apply 2x the maximum rated input pressure to the turbine for 15 minutes During the test there should be no significant leaking no loosening of parts and no potential injury conditions Higher safety factors above 2X can be considered based on your desired level of c
17. tance with the instruction manual development markings or any other assistance please let me know Pr iei GR o Sincerely Reviewed by Bill Bisenius Brad Collison Senior Project Engineer Engineering Manager 6 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Pr iri GeR o Attachment A Product Safety Hazards Overview Holden Hydro Turbine In general the product safety standards are intended to encourage products that protect the user from 6 potential hazards 1 Risk of Shock prevent access to voltages greater than 30 VRMS 42 4 Vpk or 60 VDC access determined with accessibility probes Requires 2 levels of protection to accessible circuits double or reinforced insulation between hazardous circuits and SELV circuits use power supplies with SELV certified outputs whenever possible e The turbine is mechanical only it does not incorporate any electrical circuitry Therefore it does not have voltages that are considered a risk of shock e However the turbine is intended to be connected and adjacent to an electrical generator As such the primary consideration for Risk of Shock is to protect the generator from damage caused by the turbine that could result in a shock hazard to the operator For example could the turbine leak and spray water onto electrical circuits of the generator 2 Risk of Energy prevent access to circuits capable of delivering 240 VA or more rega
18. through the air that injures a person 5 Risk of Radiation prevent limit access to sources of radiation laser UV microwave etc e There are no radiating parts in the turbine and the turbine is not intended to be used with radioactive substances 7 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G 6 Risk of Chemicals prevent limit exposure to hazardous chemicals prevent hazards from spills for products using liquids Priei Ge o The turbine is only intended for use with water and is to be located in an ordinary location no hazardous substances or fumes 8 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Pr iri GeR o Attachment B Proposed Testing Holden Hydro Turbine We have reviewed numerous guidelines for water turbines and water turbine systems During this process we identified the following water turbine tests to consider for safety compliance and product validation purposes Please review this attachment thoroughly your input is critical in selecting and defining the test program Product Families Specific differences between models should be reviewed in order to determine which model s should be tested A product family can be certified by testing select model s within the family and providing the necessary extrapolation to justify the representative testing In general worst case conditions are to be tested If a single unit can be
19. ween 50 and 100 of the maximum flow rate should be verified during validation testing A tolerance of 10 is generally acceptable Pre GR a Turbine flow efficiency a nt Urb ine i Oa dr efficiency of turbine Qa actual measured flow Qr rated flow solid line is rated curve add dashed lines to document validation points 10 901 Sheldon Drive Cary NC 27503 USA Tel 919 466 9283 Fax 919 228 4065 G Power Validation Testing Steps Please make sure that you have successfully completed this process yourselves at least once before we witness validation testing 1 Measure the flow rate into the turbine with calibrated equipment e Qactual 2 Normalize the test flow rate e Qnormalized Qactual Qrated 3 Determine the claimed efficiency at the test flow rate 4 Determine the net operating head of the turbine Hnet e Measure the gross head with calibrated equipment e Present a set of calculations showing the net head that has been calculated using the measured gross head data 5 Measure the power out from the turbine generator e True RMS voltage current and power factor e Industry preference is to use a non reactive dump load capable of dissipating the turbine output during this process 6 Use the generator efficiency curve to back calculate the turbine power output e Add in the generator losses to calculate the turbine power output e Industry practice is to also provide validat
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